Integral Fuel Tank Self-sealing Protection

The opportunity presented under this program is to develop a next-generation, self-sealing technology that can impart self-sealing capability to the most vulnerable areas of integral aircraft fuel tanks. Targeted application of the self-sealing materials will reduce the weight and fuel-volume penalty associated with conventional fuel bladder constructions. Under the Phase I program, the technical feasibility of developing lightweight, self-sealing laminate panels to support integral fuel tank protection was demonstrated. The Phase I laminates sealed straight and partially tumbled .50 caliber impacts in less than 2 minutes, even in the presence of tank petalling and fragmentation, which should be anticipated in integral fuel tank applications. Self-sealing capability was demonstrated against conventional aviation fuels as well as 50/50 blends with alternative aviation fuels. While the self-sealing materials are novel, the laminate constructions can be fabricated using manufacturing methods and materials that have proven efficacy in self-sealing fuel bladder applications conforming to MIL-DTL-5576D performance specifications. The objective of the Phase II program is to fully develop the self-sealing laminate constructions for integral fuel tank applications. Key Phase II efforts include demonstrating commercial manufacturing capability, developing and demonstrating product installation, demonstrating sub-system level threat protection performance (MIL-DTL-5576D Protection Level A,<2 minutes sealing against conventional and next-generation fuel blend), and demonstrating capability to meet operational and service life requirements.